Front suspension crown cover with connector and setting boss

ABSTRACT

A bicycle fork crown or a fork crown cover is disclosed having a connector holder with an inlet for receiving electrical cables, and an outlet for receiving an electrical connector. The connector holder retains the electrical connector and the electrical cables in a fixed position to facilitate installation and maintenance of the cables and the connection. The fork crown or the fork crown cover also includes a setting boss dimensioned to receive a connector cable terminal. The connector cable terminal can be securely fastened to the setting boss by a fastening device, such as a setting screw. In one embodiment of the invention, the fork crown includes a rubber cover that covers the terminal and the electrical connector. In another embodiment of the invention, the fork crown cover includes a pre-load adjuster cap. The fork crown cover preferably has an upper crown cover and a lower crown cover. The upper and lower crown covers can be attached together with any known fastening device.

FIELD OF THE INVENTION

[0001] The present invention relates generally to a bicycle frontsuspension crown, and more particularly to a front suspension crownhaving a setting boss and a connector cable holder.

BACKGROUND OF THE INVENTION

[0002] Modern bicycles allow the rider to control the suspension, thegears, the brakes and other features of the bicycle to optimize therider's experience. Much of the control functions are computerized sothat a rider can control the particular function by simply pressing aswitch on a control panel. A typical computerized control panel includesa base member mounted to the bicycle handlebar and numerous switches onthe control panel, each switch corresponding to a particular functionthat is controllable by the rider. Electrical cables are necessary totransmit codes from the bicycle control panel to various motors andother equipment, such as the speed sensor, torque sensor, frontsuspension and rear suspension, to carry out the function desired by therider.

[0003] In a technologically advanced bicycle, it is desirable tocomputerize the front suspension system to control the suspensioncharacter of the bicycle. An electrical suspension system, however,requires numerous cables to carry the codes to and from various motorsand devices that control the suspension system. The existence of amultitude of cables to carry out the computerized functions of thebicycle can be cumbersome and unsightly. Accordingly, there is a need toprovide a device that would manage the electrical cables of a bicycleand store the cables in a secure and organized manner.

[0004] Also, it is desirable to simplify the bicycle assembly process atthe factory or at the bicycle dealer so that the cables are notinadvertently misconnected

[0005] Furthermore, it is desirable to protect the cables from rain,dust or other element that could cause damage or wear to the electricalcables

SUMMARY OF THE PREFERRED EMBODIMENTS

[0006] The present invention overcomes the aforementioned problems byproviding a bicycle fork crown or a fork crown cover having a connectorholder with an inlet for receiving electrical cables, and an outlet forreceiving an electrical connector. The connector holder retains theelectrical connector and the electrical cables in a fixed position tofacilitate installation and maintenance of the cables and theconnection. The fork crown or the fork crown cover also includes asetting boss dimensioned to receive a connector cable terminal. Theconnector cable terminal can be securely fastened to the setting boss bya fastening device, such as a setting screw. In one embodiment of theinvention, the fork crown includes a rubber cover that covers theterminal and the electrical connector. In another embodiment of theinvention, the fork crown cover includes a pre-load adjuster cap. Thefork crown cover preferably has an upper crown cover and a lower crowncover. The upper and lower crown covers can be attached together withany known fastening device.

[0007] Other objects, features and advantages of the present inventionwill become apparent to those skilled in the art from the followingdetailed description. It is to be understood, however, that the detaileddescription and specific examples, while indicating preferredembodiments of the present invention, are given by way of illustrationand not limitation. Many changes and modifications within the scope ofthe present invention may be made without departing from the spiritthereof, and the invention includes all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The invention may be more readily understood by referring to theaccompanying drawings in which:

[0009]FIG. 1 is a plan view of an embodiment of the fork crown of thepresent invention wherein the connector, the connector cable terminal,and the setting screw are shown disconnected from the fork crown;

[0010]FIG. 2 is a front view of an embodiment of the fork crown of thepresent invention having a setting boss and a connector holder thereon;

[0011]FIG. 3 is a left side view of the embodiment of the fork crown ofthe present invention shown in FIG. 2;

[0012]FIG. 4 is a right side view of the embodiment of the fork crown ofthe present invention shown in FIG. 2;

[0013]FIG. 5 is a plan view of an embodiment of the present inventionwherein the fork crown cover includes a setting boss and a connectorholder thereon;

[0014]FIG. 6 is a front view of the embodiment of the fork crown coverof the present invention shown in FIG. 5;

[0015]FIG. 7 is a left side view of the embodiment of the fork crowncover of the present invention shown in FIG. 5;

[0016]FIG. 8 is a right side view of the embodiment of the fork crowncover of the present invention shown in FIG. 5;

[0017]FIG. 9 is an embodiment of the fork crown cover of the presentinvention having a cap for the pre-load adjuster;

[0018]FIG. 10 is front view of an embodiment of the fork crown cover ofthe present invention having a fork crown lower cover and a fork crownupper cover;

[0019]FIG. 11 is a side view of the embodiment of the fork crown coverof the present invention shown in FIG. 10;

[0020]FIG. 12 is a bottom view of an embodiment of the fork crown lowercover of the present invention set with a plurality of setting screws;

[0021]FIG. 13 is a partial view of an embodiment of the fork crown coverof the present invention wherein the upper and lower covers areconnected by flexible setting posts;

[0022]FIG. 14 is a side cross-sectional view of the embodiment of thefork crown cover of the present invention shown in FIG. 13;

[0023]FIG. 15 is a top plan view of an embodiment of the fork crown ofthe present invention having a rubber cover thereon;

[0024]FIG. 16 is a front view of the embodiment of the fork crown of thepresent invention shown in FIG. 15; and

[0025]FIG. 17 is a front view of an embodiment of the fork crown of thepresent invention having bare code with rough connection and a rubbercover thereon;

[0026] Like numerals refer to like parts throughout the several views ofthe drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0027] An exemplary embodiment of a bicycle fork crown according to theprinciples of the present invention is illustrated in FIGS. 1 through 4and identified by reference numeral 10. As best shown in FIG. 1, forkcrown 10 includes a setting boss 12 and a connector holder 14. Theconnector holder 14 has an inlet 18, best shown in FIG. 4, for receivingan electrical cable 16 a and an outlet 20, best shown in FIG. 1. Theinlet 18 of the connector holder 14 is preferably dimensioned tosecurely receive electrical cables.

[0028] As best shown in FIGS. 1 and 4, in one embodiment of theinvention, an electrical connector 22 is used to electrically connectcable 16 a with another cable 16 b. The electrical connector 22preferably has a first end 24 attachable to the outlet 20 of theconnector holder 14 and a second end 26 dimensioned to receiveelectrical cable 16 b. Connector 22 provides an electrical connectionfor cable 16 a and 16 b.

[0029] In the embodiment depicted in FIGS. 2 and 4, cable 16 a isconnected to a motor and transmits code to and from the motor. Theinvention, however, is not limited to cables that are connected to aparticular motor or other electromechanical device. Rather, theinvention can be utilized in any application wherein electrical cablesare used.

[0030] As best shown in FIGS. 1 through 3, cable 16 b is electricallyconnected to cables 16 c and 16 d via a connector cable terminal 28.Cable terminal 28 has various electrical ports 30 dimensioned to receivethe electrical cables 16 b, 16 c and 16 d. In the embodiment shown inFIGS. 1 through 3, the cable terminal 28 has three ports dimensioned toreceive the three cables 16 b, 16 c, and 16 d. In other embodiments ofthe invention, the connector cable terminal can have any number ofports, as needed to accommodate the number of electrical cables that arerequired to be electrically connected.

[0031] The setting boss 12 is dimensioned to receive the connector cableterminal 28 thereon. In a preferred embodiment of the invention, thesetting boss 12 protrudes from the surface 32 of the fork crown and isintegrally attached to the surface 32. In the embodiment shown in FIGS.1 through 3, the setting boss is shown as having a circularcross-section corresponding to a bore 34 in the connector cable terminal28. The connector cable terminal 28 is preferably mounted on the settingboss 12 and secured thereto by a fastening device 36. In a preferredembodiment of the invention, the setting boss is internally threaded tocorrespond to the external threads on a fastening device 36. Theconnector cable terminal 28 is fastened to the setting boss 12 byengaging the threads of the fastening device 36 with the internalthreads of the setting boss 12. As shown in FIG. 1, in a preferredembodiment of the invention, the fastening device 36 is a setting screw.

[0032] The connector cable terminal 28 and the centering boss 12 areshown in FIGS. 1 through 3 as having a circular cross-section. However,the invention is not limited as such and in various embodiment of theinvention, the centering boss 12 and the connector cable terminal 28 canhave any desired shape.

[0033] FIGS. 5 though 8 illustrate an alternative embodiment of thepresent invention wherein a fork crown cover 100 is placed over thebicycle fork crown 10, and the setting boss 112 and connector holder 114are attached to the fork crown cover 100, rather than the fork crown 10.The structure and electrical connections of the setting boss 112 and theconnector holder 114 are substantially similar to those described in theembodiment of FIGS. 1 through 4. Specifically, the connector holder 114has an inlet 118 for receiving an electrical cable 11 6 a and an outlet120. The inlet 118 of the connector holder 114 is preferably dimensionedto securely receive electrical cables.

[0034] An electrical connector 122 is used to electrically connect cable116 a with another cable 116 b. The electrical connector 122 preferablyhas a first end 124 attachable to the outlet 120 of the connector holder114 and a second end 126 dimensioned to receive electrical cable 116 b.Connector 122 provides an electrical connection for cable 116 a and 116b.

[0035] As best shown in FIGS. 5 and 7, cable 116 b is electricallyconnected to cables 116 c and 116 d via a connector cable terminal 128.Cable terminal 128 has various electrical ports 130 dimensioned toreceive the electrical cables 116 b, 116 c, and 116 d. In theembodiments shown in FIGS. 5 through 7, the cable terminal 128 has threeports 130 dimensioned to receive the three cables 116 b, 116 c, and 116d. In other embodiments of the invention, the connector cable terminal128 can have any number of ports, as needed to receive and connectelectrical cables.

[0036] As best shown in FIGS. 5 and 7, the setting boss 112 isdimensioned to receive the connector cable terminal 128 thereon. In apreferred embodiment of the invention, the setting boss 112 protrudesfrom the surface 132 of the fork crown cover 100 and is integrallyattached to the surface 132. In the embodiment shown in FIGS. 5 through7, the setting boss 112 is shown as having a circular cross-sectioncorresponding to a bore 134 in the connector cable terminal 128. Theconnector cable terminal 128 is preferably mounted on the setting boss112 and secured thereto by a fastening device 136. In a preferredembodiment of the present invention, the setting boss 112 is internallythreaded to correspond to the external threads on the fastening device136. The connector cable terminal 128 is preferably fastened to thesetting boss 112 by engaging the threads of the fastening device 136with the internal threads of the setting boss 112.

[0037] In another embodiment of the invention, as shown in FIG. 9, thefork crown cover 100 has a channel 138 defined therein for accessing thepre-load adjuster (not shown). By accessing the pre-load adjuster, thesuspension system can be altered to account for the rider's weight. Forexample, for a light-weight rider, the spring of the suspension systemcan be adjusted for less pre-load. For a heavy-weight rider the springof the suspension system can be adjusted to provide more pre-load. Thechannel 138 in the fork crown cover 100 allows easy access to the rideror dealer to adjust the pre-load of the spring. To prevent dirt, fluidsand other elements from damaging the pre-load adjustment mechanism, acap 140 is provided to cover the access channel 138 when the pre-loadadjustment mechanism is being used. The cap 140 is preferablydimensioned to cover the access to channel 138 and preferably includes anotch 142 therein to facilitate the removal of the cap 140 from thecrown cover 100 when access to the channel 138 is desired.

[0038] In another embodiment of the present invention, as shown in FIGS.10 and 11, the fork crown cover 100 includes a fork crown lower cover102 and a fork crown upper cover 104. The upper cover 104 preferablyincludes the setting boss 112 and connector holder 114. In analternative embodiment, the crown cover 100 can include only the uppercover 104, leaving the fork crown 10 exposed to the environment frombelow. By providing a lower cover 102, in addition to the upper cover104, the fork crown 10 is better protected from rain, dust, dirt andother elements that could cause damage to the fork crown 10 or thesuspension system generally.

[0039] The lower cover 102 can be fastened to the fork crown 10 or tothe upper crown 104 by any known fastening means. In a preferredembodiment of the invention, as shown in FIG. 12, the lower cover 102 isfastened to the fork crown 10 using setting screws 106. Other knownfastening devices can be used in place of setting screws 106.

[0040] In another preferred embodiment of the invention, as shown inFIGS. 13 and 14, upper cover 104 includes a setting aperture 108 and thelower cover includes a flexible setting post 110 dimensioned to engagewith the setting aperture 108. The flexible setting post preferably hasa latch portion 111 that protrudes into the setting aperture 108 whenthe setting post 110 is engaged with the setting aperture 108. The latchportion 111 securely fastens the upper cover 104 to the lower cover 102when the post 110 is engaged with the aperture 108.

[0041] In another preferred embodiment of the invention, as shown inFIGS. 15 and 16, a cover 150 made of a soft material is used to coverthe fork crown 10, generally, and the connector holder 14, specifically.The cover 150 is preferably made of an electrically insulative materialand more preferably is made of rubber. Some of the benefits of therubber cover 150 are that it is flexible, allowing for easy fitting overthe fork crown, and inexpensive. Additionally, if using a rubber cover150, the electrical connections can be bare code with rough connection,as shown in FIG. 17. By having bare code with rough connection, the needfor an electrical connector 22 and a connector cable terminal 28 iseliminated, further reducing the assembly cost of the electricalconnections.

What is claimed is:
 1. A bicycle fork crown for holding electricalcables, comprising a connector holder having an inlet dimensioned toreceive electrical cables.
 2. A bicycle fork crown in accordance withclaim 1, further comprising: an outlet defined in the connector holder;an electrical connector having a first end and a second end, the firstend of the electrical connector attachable to the outlet of theconnector holder, the second end of the electrical connector dimensionedto receive electrical cables; and wherein the electrical connectorprovides an electrical connection for electrical cables in the inlet ofthe connector holder to electrical cables in the second end of theelectrical connector.
 3. A bicycle fork crown in accordance with claim1, further comprising a setting boss-located apart from the connectorholder.
 4. A bicycle fork crown in accordance with claim 3 wherein thesetting boss comprises a protrusion.
 5. A bicycle fork crown inaccordance with claim 4, further comprising: a surface of the bicyclefork crown; and wherein the protrusion is integrally attached to thesurface of the bicycle fork crown.
 6. A bicycle fork crown in accordancewith claim 3 wherein the setting boss defines an internally threadedbore.
 7. A bicycle fork crown in accordance with claim 6, furthercomprising: a connector cable terminal; wherein the setting boss isdimensioned to receive the connector cable terminal; a fastening devicehaving external threads corresponding to the internally threaded bore inthe setting boss; and wherein the connector cable terminal is securelyfastened on the setting boss by tightening the threads of the fasteningdevice into the threads of the setting boss.
 8. A bicycle fork crown inaccordance with claim 2, further comprising a cable connector terminalelectrically connected to the electrical connector.
 9. A bicycle forkcrown in accordance with claim 3, further comprising a cover made of asoft material, the cover covering the electrical connector.
 10. Abicycle fork crown in accordance with claim 9 wherein the cover iselectrically insulative.
 11. A bicycle fork crown in accordance withclaim 10 wherein the cover is made of rubber.
 12. A bicycle fork crowncover for holding electrical cables, comprising a connector holderhaving an inlet dimensioned to receive electrical cables.
 13. A bicyclefork crown cover in accordance with claim 12, further comprising: anoutlet defined in the connector holder; an electrical connector having afirst end and a second end, the first end of the electrical connectorattachable to the outlet of the connector holder, the second end of theelectrical connector dimensioned to receive electrical cables; andwherein the electrical connector provides an electrical connection forelectrical cables in the inlet of the connector holder to electricalcables in the second end of the electrical connector.
 14. A bicycle forkcrown cover in accordance with claim 12, further comprising a settingboss located apart from the connector holder.
 15. A bicycle fork crowncover in accordance with claim 14 wherein the setting boss comprises aprotrusion.
 16. A bicycle fork crown cover in accordance with claim 15,further comprising: a surface of the bicycle fork crown; and wherein theprotrusion is integrally attached to the surface of the bicycle forkcrown.
 17. A bicycle fork crown cover in accordance with claim 14wherein the setting boss defines an internally threaded bore.
 18. Abicycle fork crown cover in accordance with claim 17, furthercomprising: a connector cable terminal; wherein the setting boss isdimensioned to receive the connector cable terminal; a fastening devicehaving external threads corresponding to the internally threaded bore inthe setting boss; and wherein the connector cable terminal is securelyfastened on the setting boss by tightening the threads of the fasteningdevice into the threads of the setting boss.
 19. A bicycle fork crowncover in accordance with claim 13, further comprising a cable connectorterminal electrically connected to the electrical connector.
 20. Abicycle fork crown cover in accordance with claim 13, further comprisinga pre-load adjuster cap.
 22. A bicycle fork crown cover, comprising: anupper cover; a lower cover connected to the upper cover.
 23. A bicyclefork crown cover in accordance with claim 22, wherein the lower cover isconnected to the upper cover by a fastening device.
 24. A bicycle forkcrown cover in accordance with claim 22, wherein the upper cover definesat least one setting apertures, wherein the lower cover comprises atleast one flexible setting post dimensioned to engage with the at leastone setting aperture, and wherein the lower cover is connected to theupper cover by engaging the at least one flexible setting post with theat least one setting aperture.
 25. A method of connecting electricalcables, comprising the steps of: providing a bicycle fork crown having aconnector holder and an electrical connector, wherein the connectorholder and electrical connector each have at least two portals;electrically and mechanically connecting a cable to one of the portalsin the electrical connector; electrically and mechanically connecting acable to one of the portals in the connector holder; and electricallyand mechanically connecting the electrical connector to one of theportals of the connector holder.
 26. A method in accordance with claim25, further comprising the steps of: providing a setting boss and aconnector cable terminal on the fork crown, wherein the setting boss isdimensioned to receive the connector cable terminal thereon;electrically and mechanically connecting a cable to the connector cableterminal; and installing the connector cable terminal onto the settingboss.
 27. A method of connecting electrical cables, comprising the stepsof: providing a bicycle crown cover having a connector holder and anelectrical connector, wherein the connector holder and electricalconnector each have at least two portals; electrically and mechanicallyconnecting a cable to one of the portals in the electrical connector;electrically and mechanically connecting a cable to one of the portalsin the connector holder; and electrically and mechanically connectingthe electrical connector to one of the portals of the connector holder.28. A method in accordance with claim 27, further comprising the stepsof: providing a setting boss and a connector cable terminal on the forkcrown cover, wherein the setting boss is dimensioned to receive theconnector cable terminal thereon; electrically and mechanicallyconnecting a cable to the connector cable terminal; and installing theconnector cable terminal onto the setting boss.
 29. A bicycle fork crownassembly for holding electrical cables, comprising: a fork crown; a forkcrown cover covering the fork crown; and a connector holder located onthe fork crown cover having an inlet dimensioned to receive electricalcables.
 30. A bicycle fork crown assembly in accordance with claim 29,further comprising: an outlet defined in the connector holder; anelectrical connector having a first end and a second end, the first endof the electrical connector attachable to the outlet of the connectorholder, the second end of the electrical connector dimensioned toreceive electrical cables; and wherein the electrical connector providesan electrical connection for electrical cables in the inlet of theconnector holder to electrical cables in the second end of theelectrical connector.
 31. A bicycle fork crown assembly in accordancewith claim 29, further comprising a setting boss located on the forkcrown cover.
 32. A bicycle fork crown assembly in accordance with claim31 wherein the setting boss comprises a protrusion.
 33. A bicycle forkcrown assembly in accordance with claim 32, further comprising: asurface of the fork crown cover; and wherein the protrusion isintegrally attached to the surface of the fork crown cover.
 34. Abicycle fork crown assembly in accordance with claim 31 wherein thesetting boss defines an internally threaded bore.
 35. A bicycle forkcrown assembly in accordance with claim 34, further comprising: aconnector cable terminal; wherein the setting boss is dimensioned toreceive the connector cable terminal; a fastening device having externalthreads corresponding to the internally threaded bore in the settingboss; and wherein the connector cable terminal is securely fastened onthe setting boss by tightening the threads of the fastening device intothe threads of the setting boss.
 36. A bicycle fork crown assembly inaccordance with claim 30, further comprising a cable connector terminalelectrically connected to the electrical connector.